KOMATSU AVANCE PLUS WA120-3MC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 and UP)
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KOMATSU AVANCE PLUS WA120-3MC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 and UP)
- Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death.
- Operators and maintenance personnel must read this manual thoroughly before operating or maintaining this machine.
- This manual should be kept near the machine for reference and periodically reviewed by all personnel who come across it.
- Some actions involved in operation and maintenance can cause a serious accident, if they are not performed in the manner described in this manual.
- The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual.
- Komatsu America International Company delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local distributor or Komatsu America International Company before operating the machine.
Table of Contents:
KOMATSU AVANCE PLUS WA120-3MC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A31001 and UP)
MAIN MENU........................................................................................... 0 COVER............................................................................................... 1 INTRODUCTION........................................................................................ 7 FOREWORD........................................................................................ 8 SAFETY INFORMATION.............................................................................. 9 INTRODUCTION.................................................................................... 10 INTENDED USE................................................................................ 10 FEATURES.................................................................................... 10 BREAKING IN A NEW MACHINE................................................................... 10 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................... 11 MACHINE SERIAL NO. PLATE POSITION........................................................... 11 ENGINE SERIAL NO. PLATE POSITION............................................................ 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................... 11 CONTENTS........................................................................................ 12 SAFETY.............................................................................................. 21 GENERAL PRECAUTIONS............................................................................. 22 SAFETY RULES................................................................................ 22 SAFETY FEATURES............................................................................. 22 UNAUTHORIZED MODIFICATION................................................................... 22 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................................... 23 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................................. 23 MOUNTING AND DISMOUNTING.................................................................... 24 FIRE PREVENTION FOR FUEL AND OIL............................................................ 24 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES.............................................. 25 ASBESTOS DUST HAZARD PREVENTION............................................................. 25 CRUSHING OR CUTTING PREVENTION.............................................................. 25 FIRE EXTINGUISHER AND FIRST AID KIT......................................................... 26 PRECAUTIONS WHEN USING ROPS................................................................. 26 PRECAUTIONS FOR ATTACHMENTS................................................................. 26 PRECAUTION WHEN HANDLING ACCUMULATOR........................................................ 27 PRECAUTIONS DURING OPERATION.................................................................... 28 BEFORE STARTING ENGINE...................................................................... 28 SAFETY AT WORKSITE...................................................................... 28 FIRE PREVENTION......................................................................... 28 WALK AROUND CHECK....................................................................... 28 IN OPERATOR'S CAB....................................................................... 29 VENTILATION FOR ENCLOSED AREAS.......................................................... 29 PRECAUTIONS FOR MIRRORS, WINDOWS, AND LIGHTS............................................ 29 WHEN STARTING ENGINE.................................................................... 30 AFTER STARTING ENGINE....................................................................... 31 CHECKS AFTER STARTING ENGINE............................................................ 31 PRECAUTIONS WHEN STARTING OFF........................................................... 31 CHECK WHEN CHANGING DIRECTION........................................................... 32 PRECAUTIONS WHEN TRAVELING.............................................................. 33 TRAVELING ON SLOPES..................................................................... 34 PROHIBITED OPERATIONS................................................................... 34 PRECAUTIONS WHEN TRAVELING.............................................................. 35 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.................................................. 36 ENSURE GOOD VISIBILITY.................................................................. 37 OPERATE CAREFULLY ON SNOW............................................................... 37 DO NOT HIT WORK EQUIPMENT............................................................... 37 WHEN USING THE BRAKE.................................................................... 37 WHEN TRAVELING DOWNHILL................................................................. 37 WORKING ON LOOSE GROUND................................................................. 38 PARKING THE MACHINE..................................................................... 38 PRECAUTIONS IN COLD AREAS............................................................... 39 TRANSPORTATION.............................................................................. 40 LOADING AND UNLOADING................................................................... 40 SHIPPING................................................................................ 40 BATTERY..................................................................................... 41 BATTERY HAZARD PREVENTION............................................................... 41 STARTING WITH BOOSTER CABLES............................................................ 42 CHARGING BATTERY........................................................................ 43 TOWING...................................................................................... 44 WHEN TOWING............................................................................. 44 PRECAUTIONS FOR MAINTENANCE..................................................................... 45 BEFORE CARRYING OUT MAINTENANCE............................................................. 45 NOTIFICATION OF FAILURE................................................................. 45 WARNING TAGS............................................................................ 45 CLEAN BEFORE INSPECTION AND MAINTENANCE................................................. 45 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.............................. 46 WORK EQUIPMENT SUPPORT.................................................................. 46 PROPER TOOLS............................................................................ 47 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................... 47 USE OF LIGHTING......................................................................... 47 KEEP WORK PLACE CLEAN AND TIDY.......................................................... 47 APPOINT A LEADER WHEN WORKING WITH OTHERS............................................... 48 RADIATOR WATER LEVEL.................................................................... 48 PREVENTION OF FIRE...................................................................... 48 TURN E.C.S.S. SWITCH OFF................................................................ 48 DURING MAINTENANCE.......................................................................... 49 PERSONNEL............................................................................... 49 ATTACHMENTS............................................................................. 49 WORK UNDER THE MACHINE.................................................................. 49 KEEP THE MACHINE CLEAN.................................................................. 49 DO NOT DROP TOOLS OR PARTS INSIDE MACHINE............................................... 50 PRECAUTIONS WHEN USING HAMMER........................................................... 50 REPAIR WELDING.......................................................................... 50 PRECAUTIONS WITH BATTERY................................................................ 50 WHEN ABNORMALITY IS LOCATED............................................................. 50 RULES TO FOLLOW WHEN ADDING FUEL OR OIL................................................. 51 ROTATING FAN AND BELT................................................................... 51 HANDLING HIGH-PRESSURE HOSES............................................................ 51 PRECAUTION HIGH PRESSURE OIL............................................................ 51 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE.......... 52 TIRE MAINTENANCE........................................................................ 53 CHECKS AFTER INSPECTION AND MAINTENANCE................................................. 53 WASTE MATERIALS......................................................................... 53 WHEN PERFORMING MAINTENANCE WITH THE CHASSIS RAISED..................................... 53 TIRES....................................................................................... 54 HANDLING TIRES.......................................................................... 54 STORING TIRES AFTER REMOVAL............................................................. 55 POSITION FOR ATTACHING SAFETY LABELS............................................................ 56 LOCATIONS................................................................................... 56 LABEL TEXT.................................................................................. 57 OPERATION........................................................................................... 63 GENERAL VIEW.................................................................................... 64 EXTERIOR VIEW OF MACHINE.................................................................... 64 VIEW OF CONTROLS AND GAUGES................................................................. 65 EXPLANATION OF COMPONENTS....................................................................... 67 METERS AND LAMPS............................................................................ 67 SWITCHES (ALL MODELS)....................................................................... 72 SWITCHES (MODELS WITH CAB).................................................................. 76 CONTROL LEVERS AND PEDALS................................................................... 78 MISCELLANEOUS............................................................................... 85 SAFETY BAR.............................................................................. 85 TOWING PIN.............................................................................. 85 GREASE PUMP CLAMP AND RUBBER RING....................................................... 85 BACKUP ALARM............................................................................ 85 FUSES....................................................................................... 86 FUSE CAPACITY AND NAME OF CIRCUIT....................................................... 86 SLOW-BLOW FUSES......................................................................... 87 STORING THIS MANUAL..................................................................... 88 AUXILIARY POWER SOURCE.................................................................. 88 MACHINE AND ENGINE CHECKS....................................................................... 89 CHECKS BEFORE STARTING ENGINE............................................................... 89 WALK-AROUND CHECKS...................................................................... 89 CHECK BEFORE STARTING....................................................................... 92 CHECKING AND ADDING COOLANT............................................................. 92 CHECKING THE DUST INDICATOR............................................................. 92 CHECKING THE BRAKE OIL TANK............................................................. 93 CHECKING AND ADDING ENGINE OIL.......................................................... 93 DRAINING THE FUEL-WATER SEPARATOR....................................................... 94 DRAINING THE FUEL SEDIMENT STRAINER..................................................... 94 CHECKING THE ELECTRICAL WIRING.......................................................... 95 CHECKING THE FUEL LEVEL................................................................. 95 INSPECTING THE TIRES.................................................................... 96 INSPECTING THE RIMS..................................................................... 96 CHECKING THE TIRE PRESSURE.............................................................. 96 CHECKING THE MONITOR PANEL.............................................................. 97 CHECKING THE PARKING BRAKE.............................................................. 98 CHECKING THE WHEEL BRAKES............................................................... 98 CHECK SOUND OF HORN AND BACKUP ALARM.................................................... 98 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...................................... 98 CHECK ENGINE EXHAUST COLOR AND SOUND.................................................... 98 CHECK OPERATION OF GAUGES............................................................... 98 CHECK STEERING WHEEL PLAY, CHECK STEERING OPERATION..................................... 98 CHECK THE REAR VIEW MIRROR.............................................................. 98 CHECK LOCK OF CAB DOOR (MACHINES EQUIPPED WITH CAB)..................................... 98 PRE-WORK SHIFT MACHINE CHECKS............................................................... 99 ADJUSTING THE OPERATOR'S SEAT (STANDARD VERSION)........................................ 99 ADJUSTING THE OPERATOR’S SEAT...........................................................100 (OPTIONAL AIR-RIDE SEAT)................................................................100 ADJUSTING THE SEAT BELT.................................................................101 ADJUSTING THE REAR VIEW MIRRORS.........................................................101 OPERATIONS AND CHECKS BEFORE STARTING ENGINE................................................102 STARTING THE ENGINE.............................................................................103 NORMAL STARTING PROCEDURES (IN COLD AND WARM CONDITIONS)....................................103 AFTER EXTENDED SHUTDOWN OR OIL CHANGE.......................................................104 AFTER CHANGING FUEL FILTERS.................................................................104 AFTER RUNNING OUT OF FUEL...................................................................105 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................105 OPERATING THE MACHINE...........................................................................107 MOVING THE MACHINE..........................................................................107 CHANGING THE GEAR SPEED.....................................................................109 CHANGING DIRECTION (FORWARD-REVERSE)........................................................110 AUTO-SHIFT TRANSMISSION.................................................................110 TURNING THE MACHINE.........................................................................111 STOPPING THE MACHINE........................................................................112 OPERATING THE WORK EQUIPMENT................................................................113 LIFT ARM (LEVER)........................................................................113 BUCKET (LEVER)..........................................................................114 PARKING THE MACHINE.........................................................................115 CHECKS AFTER COMPLETION OF OPERATION........................................................117 STOPPING ENGINE.............................................................................117 CHECKS AFTER STOPPING ENGINE................................................................117 LOCKING THE MACHINE.........................................................................118 TRANSPORTING THE MACHINE........................................................................119 LOADING AND UNLOADING.......................................................................119 PRECAUTIONS FOR LOADING.....................................................................120 PRECAUTIONS FOR LIFTING THE VEHICLE.........................................................120 LIFTING POINT DECALS....................................................................121 WEIGHT LIST.............................................................................121 LIFTING PROCEDURE.......................................................................122 TYPICAL WORK OPERATIONS.........................................................................123 DIGGING OPERATIONS WITH ROCK PILES..........................................................123 DIGGING OPERATIONS ON LEVEL GROUND..........................................................125 LEVELING OPERATIONS.........................................................................126 PUSHING OPERATIONS......................................................................126 STANDARD LOADING OPERATIONS.............................................................127 LOAD-AND-CARRY OPERATIONS...............................................................128 PRECAUTIONS FOR OPERATION...................................................................128 PERMISSIBLE WATER DEPTH.................................................................128 IF WHEEL BRAKE DOES NOT WORK............................................................128 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES..............................................128 PRECAUTIONS WHEN DRIVING MACHINE........................................................129 ADJUSTING THE WORK EQUIPMENT POSTURE........................................................129 ADJUSTING THE BOOM KICKOUT..............................................................129 ADJUSTING THE BUCKET POSITIONER.........................................................130 BUCKET LEVEL INDICATOR..................................................................130 COLD WEATHER OPERATIONS.........................................................................131 PRECAUTIONS DURING LOW AMBIENT TEMPERATURES.................................................131 FUEL AND LUBRICANTS.....................................................................131 COOLANT.................................................................................131 BATTERY.................................................................................132 AFTER COMPLETION OF WORK....................................................................132 AFTER COLD WEATHER HAS PASSED...............................................................132 LONG-TERM STORAGE...............................................................................133 BEFORE STORAGE..............................................................................133 DURING STORAGE..............................................................................133 AFTER STORAGE...............................................................................133 TROUBLESHOOTING.................................................................................134 MACHINE RUNS OUT OF FUEL....................................................................134 TOWING THE MACHINE..........................................................................134 ENGINE STARTS...........................................................................135 ENGINE DOES NOT START...................................................................135 DISCHARGED BATTERY..........................................................................136 BATTERY REMOVAL AND INSTALLATION........................................................137 BATTERY CHARGING PRECAUTIONS............................................................137 USING BOOSTER CABLES TO START THE ENGINE................................................138 OTHER TROUBLE...................................................................................140 ELECTRICAL SYSTEM...........................................................................140 CHASSIS.................................................................................141 ENGINE..................................................................................143 MAINTENANCE.........................................................................................145 GUIDES TO MAINTENANCE...........................................................................146 OUTLINES OF SERVICE.............................................................................148 OUTLINE OF OIL, FUEL, COOLANT...............................................................148 OIL.....................................................................................148 FUEL....................................................................................149 COOLANT.................................................................................149 GREASE..................................................................................150 STORING OIL AND FUEL....................................................................150 FILTERS.................................................................................150 FUEL INJECTION PUMP.........................................................................150 OUTLINE OF ELECTRIC SYSTEM..................................................................151 WEAR PARTS LIST.................................................................................152 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................153 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................................153 ENGINE OIL SPECIFICATIONS...................................................................154 NORMAL OPERATION........................................................................154 ARCTIC OPERATION........................................................................154 DIESEL FUEL SPECIFICATIONS..................................................................155 COOLANT SPECIFICATIONS......................................................................155 GENERAL.................................................................................155 WATER...................................................................................155 ANTIFREEZE..............................................................................156 INHIBITORS/CONDITIONERS.................................................................157 MAINTENANCE OF COOLING SYSTEM INHIBITORS................................................157 COOLANT TESTING FOR CONDITIONER CONCENTRATION...........................................157 REPLENISHING COOLANT CONDITIONER........................................................157 DCA4 UNIT MAINTENANCE GUIDE.............................................................158 COOLING SYSTEM TEST KIT.................................................................160 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...................................................161 INTRODUCTION OF NECESSARY TOOLS.............................................................161 TORQUE LIST.................................................................................162 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................163 SAFETY CRITICAL PARTS.......................................................................164 MAINTENANCE SCHEDULE CHART......................................................................167 MAINTENANCE SCHEDULE CHART..................................................................167 SERVICE PROCEDURES..............................................................................170 INITIAL 250 HOURS SERVICE...................................................................170 REPLACE FUEL FILTERS....................................................................170 REPLACE TRANSMISSION OIL FILTER ELEMENT.................................................170 REPLACE HYDRAULIC TANK FILTER ELEMENT...................................................170 WHEN REQUIRED...............................................................................171 CHECKING, CLEANING OR REPLACING THE AIR CLEANER ELEMENT.................................171 CHECKING THE TRANSMISSION OIL LEVEL, ADDING OIL.........................................173 CHECKING THE AXLE OIL LEVEL, ADDING OIL.................................................174 CLEANING THE AXLE CASE BREATHER.........................................................175 CLEANING THE RADIATOR FINS..............................................................175 REPLACING THE BOLT-ON CUTTING EDGES.....................................................176 REPLACING THE BUCKET TEETH (IF EQUIPPED)................................................177 CHECKING THE AIR CONDITIONER (IF EQUIPPED)..............................................178 CLEANING THE AIR CONDITIONER CONDENSER (IF EQUIPPED)....................................179 CHECKING THE WINDOW WASHING FLUID.......................................................179 CHECKING AND ADJUSTING THE PARKING BRAKE................................................180 REPLACING A SLOW-BLOW FUSE..............................................................181 CHECKING THE AIR INTAKE HEATER..........................................................181 CHECKS BEFORE STARTING......................................................................182 EVERY 50 HOURS SERVICE......................................................................182 DRAINING WATER AND SEDIMENT FROM THE FUEL TANK..........................................182 EVERY 100 HOURS SERVICE.....................................................................183 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK, ADDING OIL................................183 CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT...................................184 LUBRICATING.............................................................................185 EVERY 250 HOURS SERVICE.....................................................................186 CHANGING THE ENGINE OIL AND REPLACING THE ENGINE OIL FILTER.............................186 CHECKING FOR LOOSE WHEEL HUB BOLTS......................................................188 CLEANING THE AIR CONDITIONER RECIRCULATION FILTER ELEMENT...............................188 CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION......................189 CHECKING THE BATTERY ELECTROLYTE LEVEL..................................................190 CHECKING THE AIR INTAKE SYSTEM..........................................................190 LUBRICATING.............................................................................191 EVERY 500 HOURS SERVICE.....................................................................192 REPLACING THE FUEL FILTERS..............................................................192 REPLACING THE TRANSMISSION OIL FILTER ELEMENT...........................................194 LUBRICATING THE CENTER HINGE PIN........................................................195 EVERY 1,000 HOURS SERVICE...................................................................196 CHANGING THE TRANSMISSION CASE OIL, CLEANING THE STRAINER...............................196 CLEANING THE TRANSMISSION CASE BREATHER.................................................197 LUBRICATING THE FRONT, CENTER, AND REAR DRIVE SHAFTS....................................197 ADJUSTING THE ENGINE VALVE LASH CLEARANCE...............................................198 CHANGING THE HYDRAULIC TANK OIL, REPLACING THE FILTER ELEMENT...........................199 CHECKING THE FAN BELT TENSION...........................................................201 CHECKING THE FAN BELT TENSIONER BEARING AND FAN HUB BEARING; INSPECTING THE FAN BELT....201 EVERY 2,000 HOURS SERVICE...................................................................203 REPLACING COOLANT, FLUSHING THE COOLING SYSTEM..........................................203 REPLACING THE HYDRAULIC TANK BREATHER ELEMENT...........................................206 CHANGING THE AXLE OIL...................................................................206 CHECK BRAKE DISC WEAR...................................................................207 CHECK THE ALTERNATOR....................................................................207 CHECK THE STARTER MOTOR.................................................................207 CHECKING THE VIBRATION DAMPER...........................................................207 REPLACING THE AIR CONDITIONER RECIRCULATION AND.........................................207 FRESH AIR FILTER ELEMENTS...............................................................207 ADJUSTING THE ENGINE VALVE LASH CLEARANCE...............................................208 CLEANING AND CHECKING THE TURBOCHARGER..................................................210 CLEAN PPC CIRCUIT STRAINER..............................................................210 CHECK ACCUMULATOR GAS PRESSURE..........................................................210 EVERY 4,000 HOURS SERVICE...................................................................210 CHECK THE WATER PUMP....................................................................210 SPECIFICATIONS......................................................................................211 WA120-3MC Specifications........................................................................212 OPTIONS, ATTACHMENTS................................................................................215 AVAILABLE ATTACHMENTS...........................................................................216 BUCKETS AND TIRES SELECTION.....................................................................217 AIR CONDITIONING................................................................................218 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.............................................218 FAN SWITCH..............................................................................218 AIR CONDITIONER SWITCH..................................................................218 MODE SELECTOR SWITCH....................................................................219 FRESH/RECIRC SELECTOR SWITCH............................................................219 TEMPERATURE CONTROL SWITCH..............................................................219 METHOD OF OPERATION.........................................................................220 WHEN NOT USING THE AIR CONDITIONER REGULARLY...........................................220 COOL BOX....................................................................................220 ECSS (Electronically-Controlled Suspension System)..............................................221 STRUCTURE AND FUNCTION OF ECSS..............................................................221 METHOD OF OPERATING ECSS....................................................................222 PRECAUTIONS WHEN OPERATING ECSS SWITCH......................................................222 ACCUMULATOR PRECAUTIONS.....................................................................223 RADIO...........................................................................................224 OPERATING CONTROLS..........................................................................224 OPERATION...................................................................................225 SETTING THE CLOCK...........................................................................227 REMOTE CONTROL UNIT.........................................................................227 BATTERY REPLACEMENT.........................................................................228 PRECAUTIONS WHEN USING......................................................................228
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